Support straps and method of assembly for gas turbine engine

ABSTRACT

A method of assembling a portion of a gas turbine engine, includes assembling a plurality of static structure rings; attaching a plurality of support straps to an outer diameter of the plurality of static structure rings to form a cartridge; inserting the cartridge at least partially into an outer case assembly along an engine axis.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.16/032,656, filed Jul. 11, 2018.

U.S. GOVERNMENT RIGHTS

This invention was made with Government support under contractW58RGZ-16-C-0046 awarded by the United States Army. The Government hascertain rights in the invention.

BACKGROUND

The present disclosure relates generally to assembly of gas turbineengines, and more particularly to a support straps for assembly of a gasturbine engine.

Gas turbine engines include a compressor that compresses air, acombustor that burns the compressed air, and a turbine across which thecombustion gases are expanded. The expansion of the combustion gasesdrives the turbine, which in turn drives rotation of a power turbine andthe compressor.

An engine outer case assembly may include plurality case modulesconnected by flanges. A reduction in the number of modules necessarilyreduces weight thereof. The assembly may utilize axial stacking insidethe outer case so that the rotor can be balanced during assembly.However, integrating case modules complicates assembly and rotorinstallation.

SUMMARY

A method of assembling a portion of a gas turbine engine according toone disclosed non-limiting embodiment of the present disclosure includesassembling a plurality of static structure rings; attaching a pluralityof support straps to an outer diameter of the plurality of staticstructure rings to form a cartridge; and inserting the cartridge atleast partially into an outer case assembly along an engine axis.

A further aspect of the present disclosure includes that at least one ofthe plurality of static structure rings comprises a vane ring.

A further aspect of the present disclosure includes that at least one ofthe plurality of static structure rings comprises a shroud.

A further aspect of the present disclosure includes that attaching theplurality of support straps comprises attaching each of the plurality ofsupport straps parallel to the engine axis.

A further aspect of the present disclosure includes that attaching theplurality of support straps comprises attaching each of the plurality ofsupport straps to an anti-rotation feature on at least two of theplurality of static structure rings.

A further aspect of the present disclosure includes that attaching theplurality of support straps comprises attaching each of the plurality ofsupport straps through an aperture in an anti-rotation feature on atleast two of the plurality of static structure rings.

A method of assembling a portion of a gas turbine engine according toone disclosed non-limiting embodiment of the present disclosure includesforming a cartridge of a plurality of axially assembled components witha plurality of support straps and inserting the cartridge at leastpartially into an outer case assembly along an engine axis.

A further aspect of the present disclosure includes stacking a first, asecond, a third, and a fourth static structure ring; and attaching theplurality of support straps to an outer diameter of the first staticstructure ring and the fourth static structure ring to form thecartridge.

A further aspect of the present disclosure includes that the first andthe third static structure rings are vane rings.

A further aspect of the present disclosure includes that the second andthe fourth static structure rings each comprise shroud rings.

A further aspect of the present disclosure includes forming thecartridge comprises installing a rotor within the first, the second, thethird, and the fourth static structure rings.

A further aspect of the present disclosure includes installing a rotorwithin the first, the second, the third, and the fourth static structurerings.

A further aspect of the present disclosure includes attaching theplurality of support straps comprises attaching each of the plurality ofsupport straps parallel to an engine axis.

A further aspect of the present disclosure includes attaching theplurality of support straps comprises attaching each of the plurality ofsupport straps through an aperture in an anti-rotation feature on thefirst static structure ring and an aperture in an anti-rotation featureon the fourth static structure ring.

A gas turbine engine according to one disclosed non-limiting embodimentof the present disclosure includes a first static structure ring; asecond static structure ring adjacent to the first static structurering; a support strap attached to the first static structure ring andthe second static structure ring to form a cartridge; and an outer caseassembly that at least partially surrounds the cartridge.

A further aspect of the present disclosure includes that the firststatic structure ring comprises a first anti-rotation feature and thesecond static structure ring comprises a second anti-rotation feature,the support strap attached to the first anti-rotation feature and thesecond anti-rotation feature.

A further aspect of the present disclosure includes that the firststatic structure ring comprises a first anti-rotation feature and thesecond static structure ring comprises a second anti-rotation feature,the support strap at least partially extends through a first aperture inthe first anti-rotation feature and a second aperture in the secondanti-rotation feature.

A further aspect of the present disclosure includes that the supportstrap comprises a first tab in a first end section and a second tab in asecond end section.

A further aspect of the present disclosure includes that the supportstrap forms an arc between the first end section and the second endsection.

A further aspect of the present disclosure includes that the outer caseassembly is a mid-turbine frame with integral power turbine case.

A further aspect of the present disclosure includes that the secondstatic structure ring and the first static structure ring contain abalanced bladed rotor disk.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be appreciated that the following description anddrawings are intended to be exemplary in nature and non-limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the present disclosure willbecome apparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

FIG. 1 illustrates an example turboshaft gas turbine engine.

FIG. 2 illustrates a stage of the gas turbine engine.

FIG. 3 illustrates an outer case assembly for the gas turbine engine.

FIG. 4 illustrates a mid-turbine frame with integral power turbine caseaccording to one disclosed non-limiting embodiment.

FIG. 5 illustrates a partial sectional view of the plurality of staticstructure rings and rotors received within the mid-turbine frame withintegral power turbine case.

FIG. 6 is an exploded view of the plurality of static structure ringsand rotors received within the mid-turbine frame with integral powerturbine case.

FIG. 7 illustrates a method of assembling the gas turbine engine withthe plurality of support straps.

FIG. 8 illustrates a step of assembling the plurality of staticstructure rings and rotors as a cartridge to be received within themid-turbine frame with integral power turbine case.

FIG. 9 illustrates one of the support straps mounted to the cartridge.

FIG. 10 illustrates a perspective view of the cartridge.

FIG. 11 illustrates a step of assembling the plurality of staticstructure rings and rotors as a cartridge to be received within themid-turbine frame with integral power turbine case.

FIG. 12 illustrates a step of assembling the plurality of staticstructure rings and rotors as a cartridge to be received within themid-turbine frame with integral power turbine case.

FIG. 13 illustrates a step of assembling the mid-turbine frame withintegral power turbine case.

FIG. 14 illustrates a step of assembling the cartridge into themid-turbine frame with integral power turbine case.

FIG. 15 illustrates the cartridge assembled into the mid-turbine framewith integral power turbine case.

DETAILED DESCRIPTION

FIG. 1 schematically illustrates a gas turbine engine 10. In thisembodiment, the engine 10 is a three-spool turboshaft engine, such asfor a helicopter with a low spool 12, a high spool 14 and a powerturbine spool 33 mounted for rotation about an engine centrallongitudinal axis A. The engine 10 includes an inlet duct 22, acompressor section 24, a combustor section 26, a turbine section 28, anda power turbine section 34.

The compressor section 24 includes a low pressure compressor 42 with amultitude of circumferentially-spaced blades 42 a and a centrifugal highpressure compressor 44 a multitude of circumferentially-spaced blades 44a. The turbine section 28 includes a high pressure turbine 46 with amultitude of circumferentially-spaced turbine blades 46 a and a lowpressure turbine 48 with a multitude of circumferentially-spaced blades48 a.The low spool 12 includes an inner shaft 30 that interconnects thelow pressure compressor 42 and the low pressure turbine 48. The highspool 14 includes an outer shaft 31 that interconnects the high pressurecompressor 44 and the high pressure turbine 46.

The low spool 12 and the high spool 14 are mounted for rotation aboutthe engine central longitudinal axis A relative to an engine staticstructure 32 via several bearing systems 35. The power turbine spool 33is mounted for rotation about the engine central longitudinal axis A,relative to the engine static structures 22, 27, and 29 via severalbearing systems 37.

The compressor section 24 and the turbine section 28 drive the powerturbine section 34 that drives an output shaft 36. In this exampleengine, the compressor section 24 has five stages, the turbine section28 has two stages and the power turbine section 34 has three stages.During operation, the compressor section 24 draws air through the inletduct 22. In this example, the inlet duct 22 opens radially relative tothe central longitudinal axis A. The compressor section 24 compressesthe air, and the compressed air is then mixed with fuel and burned inthe combustor section 26 to form a high pressure, hot gas stream. Thehot gas stream is expanded in the turbine section 28 which rotationallydrives the compressor section 24. The hot gas stream exiting the turbinesection 28 further expands and drives the power turbine section 34 andthe output shaft 36. The compressor section 24, the combustor section26, and the turbine section 28 are often referred to as the gasgenerator, while the power turbine section 34 and the output shaft 36are referred to as the power section. Although not shown, the main shaft30 may also drive a generator or other accessories through an accessorygearbox. The gas generator creates the hot expanding gases to drive thepower section. Depending on the design, the engine accessories may bedriven either by the gas generator or by the power section. Typically,the gas generator and power section are mechanically separate such thateach rotate at different speeds appropriate for the conditions, referredto as a ‘free power turbine.’

FIG. 2 illustrates an engine stage of the gas turbine engine 10. In thisexample, the engine stage represents a portion of the power turbine 34.However, it should be appreciated that other engine sections andarchitectures will benefit herefrom. In this example, a blade 50 such asthe turbine blade (only one shown, although a plurality of blades arecircumferentially disposed about a rotor disk 51) is mounted forrotation relative to an outer case assembly 52 of the static structure32. The engine stage 40 also includes a vane ring 54 supported withinthe outer case assembly 52 upstream from the blade 50. The vane ring 54contains one or more vanes 56 that prepare the airflow for the blades.

The blade 50 includes a blade tip 58 that is located at a radiallyoutermost portion of the blade 50. The blade tip 58 includes a knifeedge 60 that extends toward a shroud 62. The shroud 62 establishes anouter radial flow path boundary of the core flow path. The knife edge 60and the shroud 62 cooperate to limit airflow leakage around the bladetip 58. The shroud 62 is disposed in an annulus radially between theouter case assembly 52 and the blade tip 58.

With reference to FIG. 3, the outer case assembly 52 includes aplurality of outer case modules 80. In this illustrated embodiment, theplurality of case modules 80 can include a mid-turbine frame withintegral power turbine case 82 (also shown in FIG. 4) with a turbineexhaust case 84 aft thereof, and one or more cases forward thereof suchas an inlet compressor case 86, and diffuser case 88. It should beappreciated that additional or alternative modules might be utilized toform the engine case assembly 52 and the assembly may be utilized inother engine sections such as the compressor section 24, the turbinesection 28, or other section.

The mid-turbine frame with integral power turbine case 82 eliminates theweight and potential leakage path of at least one bolted flange. Themid-turbine frame with integral power turbine case 82, however, requiresan assembly method that permits, for example, a power turbine rotor andstator assembly 90 (FIG. 5) to be assembled outside of the mid-turbineframe with integral power turbine case 82 as a cartridge, then beinstalled along the engine longitudinal axis A.

With reference to FIGS. 5 and 6, the power turbine rotor and statorassembly 90 generally includes a plurality of static structure rings 92.The plurality of static structure rings 92 in this example, may includea stack of a first vane ring 94, a second shroud ring 96, a third vanering 98, and a fourth shroud ring 100 (FIG. 7). The shroud rings 96, 100include shrouds to surround a respective rotor 102, 104. The pluralityof static structure rings 92 may include alternative or additionalstructures in the stack.

With reference to FIG. 7, a method 200 for assembly of the power turbinerotor and stator assembly 90 initially includes assembling (step 202;FIG. 8) the plurality of static structure rings 92 alternating withbladed rotating disks and shrouds as a stack within a forward fixture110. Next, a power turbine shaft assembly 120 is assembled to the stack(step 204).

Next, a plurality of support straps 130 (also shown in FIG. 9) areattached (step 206) to an outer diameter of the plurality of staticstructure rings 92 to form a cartridge 128 (also shown in FIG. 10). Thesupport straps 130 axially lock together the plurality of staticstructure rings 92. Access to the plurality of static structure rings 92may be through a plurality of windows 112 in the forward fixture 110which is often referred to as a “wagon wheel.”

The support straps 130 are then installed through a respective aperture122 in each anti-rotation feature 124 (FIG. 9) located on the outerdiameter of each of the first vane ring 94, the second shroud ring 96,the third vane ring 98, and the fourth shroud ring 100. Theanti-rotation features 124 position the plurality of static structurerings 92 within the engine case assembly 52. The support straps 130extend generally parallel to the engine axis A and may include, forexample five (5) straps arranged around the outer diameter thereof (FIG.10). By engaging the support straps 130 through each anti-rotationfeature 124, the support straps 130 lock together the static structurerings 92. Although an anti-rotation feature 124 is disclosed in theillustrated embodiment, other external features such as lugs may bealternatively or additionally be utilized. Further, presently existingexternal features may be modified to include an aperture 122 thatreceives the respective support strap 130.

The support straps 130 may be manufactured of Inconel or other hightemperature resistant material. Each support strap 130 may be formedwith a first tab 132 in a first end section 134 and a second tab 136 ina second end section 138 and an arc 140 between the first end section134 and the second end section 138 (FIG. 9) once installed. The tabs132, 136 may be bent during installation. The support straps 130 neednot have any function during engine operation and may move radially withthe plurality of static structure rings 92 during thermal transients.Further, no path to the core flowpath exists should the support strap130 fracture.

Once the support straps 130 are installed and the tabs 132, 136 are bentto lock each the support straps 130 in place, a forward balance bearing150 (step 208; FIG. 8) is installed to the first fixture 110 to receivethe cartridge 128.

Next, a rear fixture 152 is assembled (step 210; FIG. 11) to thecartridge 128 and the forward fixture 110. The rear fixture 152 is thenclamped (step 212; FIG. 11) to the fourth shroud ring 100 via clamps154.

Next, an aft balance bearing 156 is installed (step 214; FIG. 11) to therear fixture 110.

The cartridge 128 may then be balance checked (step 216; FIG. 11). Thebalance may be adjusted through, for example, removal, trim, andreinstallation of balance rings 107 (FIG. 6) as required (step 218).Access windows in the fixtures 110, 152 permit the balance rings to beremoved and reinstalled.

Once balanced, the rear balance bearing 156 is removed (step 220; FIG.12) and a shaft retainer 160 is installed (step 222; FIG. 12). Thebalanced cartridge 128 is then removed from the forward fixture 110 thenthe front balance bearing 150 is removed and the engine bearing 157 andseal 158 are added to the shaft 120. The balanced cartridge 128 is thentransferred (step 224; FIG. 13) to the mid-turbine frame with integralpower turbine case 82. It should be appreciated that although certainprimary steps are disclosed, other steps and/or component assembly anddisassembly may also be required but are not specifically disclosed inthis illustrated embodiment.

In one example, the mid-turbine frame with integral power turbine case82 initially receives a power turbine shroud shroud ring 174 assembledinto the mid-turbine frame with integral power turbine case 82 (step228; FIG. 13).

Next, the balanced cartridge 128 (shown in FIG. 14) with the supportstraps 130 in place is then installed into the mid-turbine frame withintegral power turbine case 82 (step 230;). The rear fixture 152 maythen be removed (step 232) once the balanced cartridge 128 is installedinto the mid-turbine frame with integral power turbine case 82. Finally,an aft module such as the turbine exhaust case 84, is assembled (step234; FIG. 15) to the mid-turbine frame with integral power turbine case82. Various other components may be assembled thereto as well.

The support straps 130 thereby readily facilitate configuration of thecartridge 128 and thus insertion and removal from the integrated casemodule. Typically, the support straps 130 are discarded after a singleuse due to the requirement to bend the tab at assembly.

Although a combination of features is shown in the illustrated examples,not all of them need to be combined to realize the benefits of variousembodiments of this disclosure. In other words, a system designedaccording to an embodiment of this disclosure will not necessarilyinclude all of the features shown in any one of the figures or all ofthe portions schematically shown in the figures. Moreover, selectedfeatures of one example embodiment may be combined with selectedfeatures of other example embodiments.

The elements described and depicted herein, including in flow charts andblock diagrams throughout the figures may show logical boundariesbetween the elements. However, according to software or hardwareengineering practices, the depicted elements and the functions thereofmay be implemented on machines through computer executable media havinga processor capable of executing program instructions stored thereon asa monolithic software structure, as standalone software modules, or asmodules that employ external routines, code, services, and so forth, orany combination of these, and all such implementations may be within thescope of the present disclosure.

The use of the terms “a”, “an”, “the”, and similar references in thecontext of description (especially in the context of the followingclaims) are to be construed to cover both the singular and the plural,unless otherwise indicated herein or specifically contradicted bycontext. The modifier “about” used in connection with a quantity isinclusive of the stated value and has the meaning dictated by thecontext (e.g., it includes the degree of error associated withmeasurement of the particular quantity). All ranges disclosed herein areinclusive of the endpoints, and the endpoints are independentlycombinable with each other.

Although the different non-limiting embodiments have specificillustrated components, the embodiments of this invention are notlimited to those particular combinations. It is possible to use some ofthe components or features from any of the non-limiting embodiments incombination with features or components from any of the othernon-limiting embodiments.

It should be appreciated that like reference numerals identifycorresponding or similar elements throughout the several drawings. Itshould also be appreciated that although a particular componentarrangement is disclosed in the illustrated embodiment, otherarrangements will benefit herefrom.

Although particular step sequences are shown, described, and claimed, itshould be understood that steps may be performed in any order, separatedor combined unless otherwise indicated and will still benefit from thepresent disclosure.

The foregoing description is exemplary rather than defined by thelimitations within. Various non-limiting embodiments are disclosedherein, however, one of ordinary skill in the art would recognize thatvarious modifications and variations in light of the above teachingswill fall within the scope of the appended claims. It is therefore to beunderstood that within the scope of the appended claims, the disclosuremay be practiced other than as specifically described. For that reason,the appended claims should be studied to determine true scope andcontent.

1-20. (canceled)
 21. A method of assembling a portion of a gas turbineengine, comprising: assembling a plurality of static structure rings;attaching an outer diameter of the plurality of static structure ringsto form a cartridge; and inserting the cartridge at least partially intoan outer case assembly along an engine axis.
 22. The method as recitedin claim 21, wherein at least one of the plurality of static structurerings comprises a vane ring.
 23. The method as recited in claim 21,wherein at least one of the plurality of static structure ringscomprises a blade outer air seal.
 24. The method as recited in claim 21,wherein attaching the outer diameter of the plurality of staticstructure rings comprises attaching at an anti-rotation feature on atleast two of the plurality of static structure rings.
 25. The method asrecited in claim 21, wherein forming the cartridge comprises installinga balanced rotor within the plurality of static structure rings.
 26. Themethod as recited in claim 21, wherein the outer case assembly is amid-turbine frame with integral power turbine case.
 27. A gas turbineengine, comprising: a cartridge formed of a plurality of staticstructure rings and a balanced bladed rotor disk along an axis; and anouter case assembly that at least partially surrounds the cartridge. 28.The gas turbine engine as recited in claim 27, wherein the plurality ofstatic structure rings comprise: a first static structure ring; and asecond static structure ring adjacent to the first static structurering.
 29. The gas turbine engine as recited in claim 28, wherein thefirst static structure ring comprises a first anti-rotation feature andthe second static structure ring comprises a second anti-rotationfeature, the first anti-rotation feature attached to the secondanti-rotation feature.
 30. The gas turbine engine as recited in claim27, wherein the outer case assembly is a mid-turbine frame with integralpower turbine case.